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Forums › Tuning, Modification & Legal › Project Cars › Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent repair


 
 

Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent repair
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Sim
PostPosted: Sat Dec 16, 2017 4:41 pm Up
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Posts: 927
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Location: Bristol


Back in 2016 been pondering what kind of first car could my missus have. Knowing the colour she'd want in, weighing fun, garageability, ICE, 206, newish, and few other factors, after numerous candidates I decided to sneak out to a salvage yard and bring a CC back to the 2nd life:

 


Boxes ticked:
☑ Black is the new black
☑ Well preserved leather interior
☑ Fun drop top for summers
☑ Repairable
☑ JBL sound system as optional extra from factory (including elongated sub in the boot)
☑ It's a 206! (really..)
☑ Year 2007
☑ 62,700 on the clock
☑ £650

The damage done was this side scrape (looks worse than it is):

 


and a failed power steering pump (from running dry) -- it had lost the PAS fluid when its pressure sensor (aiding the ESP/ASR system) blew apart:

 


What could have caused this to happen? Trapped air when low on fluid? Soaring temperatures of heatwaves in summer of '16? Confused

After hiding Symio at the unit, sourcing the spares, and repairing when work on the garage permitted (or not), one year later this CC has been brought up to somewhat presentable and revealed to my unaware missus for her birthday:

 


Next up I'll write about how it was to straighten the dents and do the preliminary electric PAS pump conversion (the latter will get condensed into a HOW-TO)

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (doing her up more after bedding her in)
PSA's GTC VXR, year 2014 (weekend toy)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)

Last edited by Sim on Mon May 21, 2018 11:30 pm; edited 1 time in total
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Sim
PostPosted: Mon May 14, 2018 12:35 pm Up
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Posts: 927
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Location: Bristol


Fast-forward to the last weekend, Project Binky style bracket done:
 


Bolt-on pump:
 


Run-in tests to commence tonight, can't wait! \o/

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (doing her up more after bedding her in)
PSA's GTC VXR, year 2014 (weekend toy)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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Sim
PostPosted: Mon May 21, 2018 2:48 pm Up
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Posts: 927
Trade Rating: 0
Location: Bristol


You can see from previous photo that cambelt sprockets are exposed, decided to tidy that up, which meant sprockets off, meaning new cambelt, meaning new waterpump, meaning coolant change, meaning "Hal fixing a lightbulb". Was due for cambelt anyway due to no service history from that salvage yard and the mileage.

 


Yet absolutely loved the engine's designation cast print proudly shining!

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (doing her up more after bedding her in)
PSA's GTC VXR, year 2014 (weekend toy)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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Sim
PostPosted: Mon May 21, 2018 11:25 pm Up
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Joined: Jun 20, 2012
Posts: 927
Trade Rating: 0
Location: Bristol


TU5JP4 (1.6 16v NFU) cambelt replacement instructions are not in 206 Haynes manual, but they are in the 307 one Razz ..and Autodata is your friend, always. As well as this guy.

Locking up the crankshaft was another pain point, Haynes showing even exhaust manifold removed for easier access. But by the looks of it, oil filter might have to come off, especially if the hole into the flywheel has gunked up with rust.

The middle torx bolt that fixes the inner cambelt cover in place had a small oil leak. I realised it had't been done up properly! Or had come undone due to the oil collecting behind it.

 


Looks like the cast has been machined up to the very area of the oil gallery itself, so I dried it up as much as possible, dabbed some thread locker, tightened to 22 Nm and hope the oil'll never come back through Smile

The amount of cursing and bashing that the old water pump took was immense. It just caked up from all possible deposits within + time. Initial impactful prying resulted in this: Very Happy

 


Finally found an angle where to place the crowbar and leverage it out, to be honest wouldn't know how to proceed, had the cambelt inner cover was still on (that poor plastic wouldn't take the pressure for sure).

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (doing her up more after bedding her in)
PSA's GTC VXR, year 2014 (weekend toy)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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Sim
PostPosted: Mon May 28, 2018 12:58 pm Up
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Joined: Jun 20, 2012
Posts: 927
Trade Rating: 0
Location: Bristol


That rewarding engine sound when you don't hear misfires or worse clunking after your first cambelt change Very Happy youtu.be/FHIE-N3Qr5M
2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (doing her up more after bedding her in)
PSA's GTC VXR, year 2014 (weekend toy)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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Sim
PostPosted: Fri Jun 01, 2018 6:24 am Up
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Joined: Jun 20, 2012
Posts: 927
Trade Rating: 0
Location: Bristol


What the hell did just happen Click here?

Linking out due to some gruesome imagery if misinterpreted Smile

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (doing her up more after bedding her in)
PSA's GTC VXR, year 2014 (weekend toy)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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Sim
PostPosted: Wed Jun 13, 2018 4:15 pm Up
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Joined: Jun 20, 2012
Posts: 927
Trade Rating: 0
Location: Bristol


With all original Citroen ePAS pump loom in place (relay on the far left of the photo), and a new earthpoint reusing a hole in the radiator housing, this part of the project concluded:

 


The MOT bucket list was surprisingly short, to replace the O/S/F wishbone.
What could possibly go wrong?

Well, one of the wishbone/subframe steel bolts had seized in, essentially fused itself with the aluminium tubing that sits inside the bush.
So there's no way of getting the bugger out, except for dropping subframe or trying some whacky grinding...
Has anyone been in such a messy situation before? Smile

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (doing her up more after bedding her in)
PSA's GTC VXR, year 2014 (weekend toy)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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Sim
PostPosted: Thu Jul 12, 2018 10:56 am Up
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Joined: Jun 20, 2012
Posts: 927
Trade Rating: 0
Location: Bristol


The seized wishbone bolt has surrendered to the slide hammer, subframe slightly bowed out, but went back in place as the new bolt got the grip.

One week after Pugfest, CarPro's PERL is still holding up nicely, not having gone overboard with it either way
 

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (doing her up more after bedding her in)
PSA's GTC VXR, year 2014 (weekend toy)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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